IMPLEMENTATION OF REDUCED FUEL CONSUMPTION IN CEMENT KILN WITH EFFICIENT COOLING TECHNOLOGY USING PLC AND HUMAN MACHINE INTERFACE

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1 International Journal of Civil Engineering and Technology (IJCIET) Volume 9, Issue 11, November 2018, pp , Article ID: IJCIET_09_11_152 Available online at ISSN Print: and ISSN Online: IAEME PublicationScopus Indexed IMPLEMENTATION OF REDUCED FUEL CONSUMPTION IN CEMENT KILN WITH EFFICIENT COOLING TECHNOLOGY USING PLC AND HUMAN MACHINE INTERFACE Dr.P.Maniraj Kumar, K.Ramamoorthy, S.Karthikeyan and T.Chelladurai PSNA College of Engineering and Technology, Dindigul ABSTRACT Cement is the most important essential component to the building infrastructure development. Taking into consideration that the bond market will record an expanding rate of 15-20%, identified with the private structures improvement and to the start of extensive foundation extends the concrete creation is of extraordinary premium, both from the perspective of item's quality increment and crude material utilization. The main objective of this paper is to show how the process model can be inserted into advanced controllers to allow the successful control and optimization of the process, thereby upgrading the new technologies to the cement kiln, hot air from the Grate cooler is recycled to the Pre-heater, in order to reduce the fuel consumption in burner and high production rate of the cement can be achieved. The cement kiln consists of DRY and WET process. Initially, in pyro-processing the raw mix is fed into cement kiln and heated up to 1500( 0 C) in the presence of limited supply of oxygen, the resultant clinker is now allowed to cool down up to 100( 0 C). Waste hot air from the Grate cooler is recycled to the Pre-heater, in order to reduce the fuel consumption in burner. Process mechanization is the place the modern territory offers the greatest and most fulfilling challenges as far as joining customary building abilities with mechanical development. The cement kiln is enhanced with the new technology using PLC (Programmable Logic Controller) and the output is monitored and controlled with the help of the HMI (Human Machine Interface). The whole system has been implemented and tested using Siemen s PLC. Keywords: Cement kiln, control system, clinker cooling, HMI, heat recovery unit, PLC, PYRO processing. Cite this Article: Dr.P.Maniraj Kumar, K.Ramamoorthy, S.Karthikeyan and T.Chelladurai, Implementation of Reduced Fuel Consumption in Cement Kiln with Efficient Cooling Technology Using Plc. and Human Machine Interface, International Journal of Civil Engineering and Technology, 9(11), 2018, pp editor@iaeme.com

2 Implementation of Reduced Fuel Consumption in Cement Kiln with Efficient Cooling Technology Using Plc and Human Machine Interface 1. INTRODUCTION India is the second largest producer of cement in the world. Cement is an essential component of infrastructure development. India has a lot of potential for development in the infrastructure and construction sector and the cement sector is expected to largely benefit from it. The availability of the raw materials such as limestone and coal aids higher growth in this sector. A cement is a binder, a substance used in construction that sets, hardens and adheres to other, Setting time and "early strength" are important characteristics of cements. The main three makers were China with 1,800, India with 220, and USA with 63.5 million tones for a joined aggregate of over a large portion of the world aggregate. In this Process the overall concept of the Cement Rotatory Kiln Process is taken from the various cement manufacturing groups of India Cement manufacture process consists broadly of different stages, Mining, Crushing and Grinding a mixture of Raw Materials to make a fine rawmix, Blending, Pyro Processing (i.e.) Heating the rawmix to sintering temperature (up to 1500 degree Celsius) in a cement kiln, Clinker Cooling and Storage, Grinding the resulting clinker to make cement, Packing and Loading. This paper reviews only the Pyro processing and Cooling Technology, where the waste hot air from the Grate cooler is recycled to the Preheater, in order to reduce the fuel consumption in burner. The rawmix is fed into the kiln and gradually heated by contact with the hot gases from combustion of the kiln fuel. The raw material is melted to a high temperature makes the raw mix to change its chemical reaction to get the resultant nodules of diameter 1-10mm. This is called clinker. The hot clinker next falls into a Grate cooler which recovers most of its heat, and cools the clinker to around 100 degree Celsius. The recovered heat is recycled to reduce the Fuel consumption in the burner. The whole Automation Process is designed with the help of Siemens 1200 series PLC TIA Portal and the output is monitored with HMI (Human Machine Interface). 2. CEMENT PROCESS FLOW Figure 1 Process flow chart of cement plant The Cement manufacture process consists broadly of different stages, Mining, Crushing and Grinding a mixture of Raw Materials to make a fine rawmix, Blending, Pyro Processing (i.e.) Heating the rawmix to sintering temperature (up to 1500 degree Celsius) in a cement kiln, Clinker Cooling and Storage, Grinding the resulting clinker to make cement, Packing and Loading. In the above Figure.1 Process Flow chart, this paper considers only the kiln and clinker cooling process. The rawmix is fed into the kiln and gradually heated by contact with the hot gases from combustion of the kiln fuel. The melting causes the material into lumps or editor@iaeme.com

3 Dr.P.Maniraj Kumar, K.Ramamoorthy, S.Karthikeyan and T.Chelladurai nodules, typically of diameter 1-10mm.This is called clinker. The hot clinker next falls into a cooler which recovers most of its heat, and cools the clinker to around 100 o C. During the Pyro Processing, Calcination of Lime takes place in the cement rotatory kiln due to high temperature. This Thermal treatment process carried out in the absence of or limited supply of air or oxygen to the rawmix to bring about the Thermal decomposition. The temperature of the kiln is controlled by PLC. The temperature inside the kiln bed is maintained and carbon dioxide is exhausted to control the calcination process. The output is monitored and some control command is given through the HMI. 3. PROPOSED WORK This representation refers to a dry and wet process of kiln. The kiln is 180 m long and 6 m in diameter, and mounted inclined to 4º angle about its axis, rotates around 3-5 Revolutions per minute. It is necessary that the mix move slowly enough to allow each reaction to be completed at the appropriate temperature. Inside the kiln the chemical decomposition takes place because of limited supply of oxygen or absence of air. Heat recover from the cooling system is transferred to a precalciner via tertiary airduct to heat the raw mix initially thereby reducing the fuel consumption. Figure 2 Block Diagram of kiln with tertiary air duct 3.1. Calcination Process Calcination responses for the most part occur at or over the warm deterioration temperature. This temperature is generally characterized as the temperature at which the standard Gibbs free vitality for a specific calcination response is equivalent to zero. For instance, in limestone calcination, a disintegration procedure, the substance response is CaCO3 CaO + CO2 (g) Grate Cooling Technology Mesh coolers are generally utilized as a part of bond industry to recoup warm from hot clinkers leaving turning ovens. The performance of the rotary kiln is indirectly controlled by heat transfer in the cooler system. The outlet temperature of hot clinkers and a part of melt coming out from the rotary kiln is approximately 1946 Kelvin. These hot lumbs should be cooled to a temperature around 673 Kelvin, by recovering heat from them, which can be used editor@iaeme.com

4 Implementation of Reduced Fuel Consumption in Cement Kiln with Efficient Cooling Technology Using Plc and Human Machine Interface for any other process. By extracting heat from the clinker the energy consumption is reduced for heating the premix Programmable Logic Controller In 1960 s PLC where introduced, MODICON 084 was the world first PLC as commercial product to the US car Manufacturer. The object of automation is safety, reliability, efficiency and less time consumption. PLC as a tool for automation is focused here. The National Electrical Manufacturers Association (NEMA) characterizes a PLC as "a carefully working electronic mechanical assembly which utilizes a programmable memory for the interior stockpiling of guidelines for actualizing particular capacities, for example, rationale, sequencing, timing, checking and math to control through computerized or simple info/yield modules, different sorts of machines or procedures". In other terms PLC can be define as a PC designed for an environment. Programming is done with the help of ladder logic language. Siemens 1200 series Controller is used to control the process. Basics concept of relay working plays the main role in the programming (i.e.,) NO (Normally Open) and NC (Normally Closed) Contacts. NO and NC Contacts are consider as the input and Coil is used to indicate the Output Architecture of PLC A PLC will always consist of input and output interfaces, memory, a power supply and housing functionally. Fig.3.1 shows the architecture of a PLC. A PLC examines the status of input interfaces and in response and controls something through output interfaces. Combinations of input and output data are referred to as logic. Several logic combinations are usually needed to carry out a program or control plan.the control plan is stored in memory using a programming device. Figure 3 PLC architecture 3.5. PID Controller A proportional integral subordinate controller (PID controller or three term controller) is a control circle criticism instrument generally utilized as a part of modern control frameworks to get the coveted controlled yield. A PID controller persistently ascertains a mistake an incentive as the distinction between a coveted set point and a deliberate procedure variable and applies a redress in light of corresponding, indispensable, and subsidiary terms (meant P, I, and D individually) editor@iaeme.com

5 Dr.P.Maniraj Kumar, K.Ramamoorthy, S.Karthikeyan and T.Chelladurai Figure 4 PID Controller action Figure 5 Front pannel HMI screen editor@iaeme.com

6 Implementation of Reduced Fuel Consumption in Cement Kiln with Efficient Cooling Technology Using Plc and Human Machine Interface Figure 6 Fuel Consumption based on recovered heat (a) At Minimum Temperature, (b) At Maximum Temperature 4. RESULTS AND DISCUSSION In the HMI window we can see the current status of the Process. We can see the status of the burner, motor, exhaust fan and the inlet valve of the KILN. Initially the kiln gets started after some delay the Inlet valve and Burner turns on based on the temperature of the clinker the fuel level is controlled. Exhaust fan gets started when the Co2 level gradually increases inside the kiln. The below table 5.1 shows the status of the process. Table 1 Status of the Process Unit Kiln Burner Exhaust Fan Inlet Valve Motor Fuel Status Of The Unit On On On On 3 Rpm (Off) 5 Rpm (On) (1) High Fuel (On) (2) Low Fuel (Off) 5. CONCLUSION The proposed work conclude that cement kiln is heated up to 1500( 0 C) in the presence of limited supply of oxygen, the resultant clinker is now allowed to cool down up to 100( 0 C) Waste hot air from the Grate cooler is recycled to the Pre-heater and reduce the fuel editor@iaeme.com

7 Dr.P.Maniraj Kumar, K.Ramamoorthy, S.Karthikeyan and T.Chelladurai consumption in burner. Measured signal is fed into the Programmable Logic Controller and the action takes place to get the desired output. Thus the Graphical representation of the results for Fuel Consumption is reduced in the burner by the recovered heat and the whole process is monitored with Human Machine Interface. REFERENCES Table 2 Comparison Table for Fuel Consumption based on Recovered Heat Recycled Temperature Fuel Consumption ( 0 C) (Ml) [1] Bentsen B, Jespersen M, Keefe BP & Shenk RE, The originator of modern clinker cooler designs: past, present and future developments, IEEE Conference Record Cement Industry Technical Conference, (2005), pp [2] Zhang J, Meng Q & Yu H, The Application of Dynamic Matrix Control in the Grate Cooler, IEEE 2 nd Advanced Information Technology, Electronic and Automation Control Conference (IAEAC), (2013). [3] Li S, Li R & Liu W, The application of expert system and fuzzy Fig. 6: Temperature and Co2 monitoring control system in cement grate cooler system, IEEE 7th IEEE International Conference on Software Engineering and Service Science (ICSESS), (2016), pp [4] Amiri a& Vaseghi MR, Waste heat recovery power generation systems for cement production process, IEEE Transactions on Industry Applications, Vol.51, No.1, (2015), pp [5] Carichner D & Murphy NJ. Third generation clinker cooler for reduced operating and maintenance cost. IEEE-IAS/PCA Conference on Cement Industry Technical, (2017), pp.1-9. [6] Mirolli MD, Ammonia-water based thermal conversion technology: Applications in waste heat recovery for the cement industry, Cement Industry Technical Conference Record, (2007), pp [7] Qiao J & Chai T, Intelligence-based pressure switching control for clinker cooling process with grate cooler, Control and Decision Conference (CCDC), (2016), pp [8] Wen Y & Li H, Simulation and Experiment on Cement Clinker Flowing Law in a New Type Grate Cooler, IEEE International Conference on Engineering Computation, (2009), pp [9] Chen G, Xu M, Liu T, Ni J, Xie D & Zhang Y, Intelligent Control System of Transformer Cooling Based on DCS and Dual PLC, [10] [10]Fifth International Conference on Measuring Technology and Mechatronics Automation (ICMTMA), (2013), pp [11] Gagnon D, Upgrading a clinker cooler IKN Klinker Inlet Distribution System (" KIDS"), IEEE Transactions on Industry Applications, Vol.33, No.1, (1997), pp editor@iaeme.com

8 Implementation of Reduced Fuel Consumption in Cement Kiln with Efficient Cooling Technology Using Plc and Human Machine Interface [12] Pai S, Bansal N, Desai K, Doshi A, Moharkar D & Pathare M, Intelligent PLC based transformer cooling control system, IEEE International Conference on Nascent Technologies in Engineering (ICNTE), (2017), pp.1-6. [13] Bin L & Hai Z, Study on Measurement System of Cement Cooler Clinker's Temperature Field, 2nd IEEE/ASME International Conference on Mechatronics and Embedded Systems and Applications, (2006), pp editor@iaeme.com